API 936– Model Exam

Name of Candidate : Date :

Time Start : Time End :

Please read the following notes:

There are four possible answers for each question (a,b,c &d) and only one is correct. Use pen or pencil to ‘√’ your answer
on the LINE, provided in front of each question. Marks: 100 x 1 = 100

Question 1: The main purpose of curing a castable is to

a). _____Harden the surface of the castable
b) _____ Protect the green castable from air pollution
c) _____ Keep the castable cool
√ Prevent the castable from drying out too quickly
d) _____

Question 2: Plastic refractory should

a). _____have low emissivity
b) _____ have low drying and firing shrinkage
c) _____
√ have high workability
d) _____ have a high fusion point

Question 3: Three of the following are ways in which steel fibre assists monolithic linings. Which one is not
a). _____Improves abrasion resistance
b) _____
√ Improves thermal resistance
c) _____ Improves tensile strength
d) _____ Improves thermal shock resistance

Question 4: The practical site test to determine the correct consistency of a castable is called
a). _____The slump test
b) _____ The compacting factor test
√ The hand ball test
c) _____
d) _____ The compressive test

Question 5: The main cause of spalling is

a). _____Slag attack
b) _____
√ Differential expansion
c) _____ Poor Design
d) _____ High thermal conductivity

Question 6: The pyrometric cone reports refractories in terms of

a). _____Density
b) _____ Thermal Expansion
√ Temperature
c) _____
d) _____ Conduction

Question 7: One of the main disadvantage of gunning application is

a). _____Rapid installation
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 API 936– Model Exam
b) _____ No form work is required
√ High level of rebound
c) _____
d) _____ No vibration

Question 8: The formula of Kaolinite is

a). _____Al2O3 4SiO2 H2O
√ Al2O3 2SiO2 2H2O
b) _____
c) _____ Al2O3 2SiO2 H2O
d) _____ 2Al2O3 2SiO2 H2O

Question 9: What is the type of refractory called when silica content is more
a). _____Basic refractories
b) _____ Neutral refractories
c) _____
√ Acid refractories
d) _____ Mullite refractories

Question 10: Abrasion resistant lining on hex-mesh is widely in practice on the following equipment
a). _____SRU thermal incinerator
b) _____ Coke oven battery
c) _____
√ FCCU Cyclones
d) _____ WHB tube sheet

Question 11: Fusion or melting of refractory material as a result of chemical action is

a). _____Slagging
√ Fluxing
b) _____
c) _____ Corrosion
d) _____ Bloating

Question 12: A natural or synthetic mineral theoretically consisting solely of aluminia is

a). _____Carborundum
b) _____ Spinal
√ Coroundum
c) _____
d) _____ Kaolin

Question 13: A plane of weakness within a monolithic refractory lining that is parallel to the hotface of the lining and
permits separation into layers is
a). _____Carck
b) _____ Pinch spalling
c) _____
√ Lamination
d) _____ Segregation

Question 14: Fireclay brick which has a PCE not lower than Cone 15, nor higher than Cone 28 - 29 is
a). _____Super-duty fireclay brick
b) _____ Medium-duty fireclay brick
c) _____
√ Low-duty fireclay brick
d) _____ High-duty fireclay brick

Question 15: A condition describing a refractory lining that is soft and friable is
a). _____Pinky
b) _____ Spongy
c) _____
√ Punky
d) _____ Pumpy

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 API 936– Model Exam
Question 16: The vertical distance between the level of the spring line and the highest point of the under surface of an
arch is
a). _____Span
b) _____ Haunch
c) _____ Crown
√ Rise
d) _____

Question 17: Spalling of layers from the hot face of a refractory lining is
a). _____Pinching
√ Sheeting
b) _____
c) _____ Setting
d) _____ Warping

Question 18: An atmosphere that, at high temperature, lowers the state of oxidation of exposed material is
a). _____Basic atmosphere
b) _____ Oxidising atmosphere
c) _____
√ Reducing atmosphere
d) _____ Acidic atmosphere

Question 19: Individual at the point of application in a dry gun operation who controls water addition is called as
a). _____Water man
b) _____ Gun man
√ Nozzle man
c) _____
d) _____ Spray man

Question 20: a group of rock mineral having nearly perfect cleavage in one direction and consisting of thin elastic
plates and the most common varieties are biotite and muscovite is
a). _____Vermiculite
b) _____ Perlite
√ Mica
c) _____
d) _____ Mullite

Question 21: The one-thousandth part of a millimetre, a unit of measurement used in microscopy is
a). _____Macron
b) _____ Million
c) _____ Electron
√ Micron
d) _____

Question 22: Time dependent deformation due to sustained load of refractory is

√
a). _____Creep
b) _____ Refractoriness
c) _____ Thermal Shock
d) _____ Modulus of Rupture

Question 23: The change from glassy state to crystalline condition is called as
a). _____Crystal formation
√ Devitrification
b) _____
c) _____ Vitrification
d) _____ Sintering

Question 24: Wearing away of the surfaces of refractory lining in service by the scouring action of moving solids is
a). _____Erosion
b) _____
√ Abrasion
c) _____ Corrosion

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 API 936– Model Exam
d) _____ Loss on Ignition

Question 25: A standard brick shape whose thickness tapers along its width is called as
√
a). _____Arch brick
b) _____ Key brick
c) _____ Wedge brick
d) _____ Standard brick

Question 26: A flat or sloped portion of a fired heater radiant section opposite to floor is
a). _____Arch
√
b) _____ Radiant wall
c) _____ Convection
d) _____ Flat

Question 27: Quantity of catable refractory produced by a single blending or mixing operation either during field
mixing is known as
a). _____ Blend
b) _____
√ Batch
c) _____ Mix
d) _____ Lot

Question 28: Dissociation of a compound on heating, with the formation of another compound and a liquid each
having a different composition from the original compound is
a). _____
√ Incongruent melting
b) _____ Refractoriness Under Load
c) _____ Carbon monoxide disintegration
d) _____ Devitrification

Question 29: A standard brick shape whose width tapers along its length is
a). _____Key
√ brick
b) _____ Wedge
c) _____ Arch
d) _____ Flat curve

Question 30: A refractory piece formed by a hexmesh cell during lining installation that has a hexagonal shape and the
thickness of the hexmesh lining is called as
a). _____Sample
b) _____ Specimen
c) _____
√ Biscuit
d) _____ Bisque

Question 31: A fireclay brick containing not less than 72% silica is
a). _____Firebrick
b) _____ Silica brick
c) _____ Superduty Firebrick
d) _____
√ Semi-silica brick
Question 32: An arch, which is supported by abutments at the side or ends only is
a). _____Suspended arch
b) _____ Flat arch
√ Sprung arch
c) _____
d) _____ Dome

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 API 936– Model Exam
Question 33: The exposure of a refractory material to a rapid change in temperature, which may have deleterious effect
is called as
a). _____Thermal Spalling
√ Thermal Shock
b) _____
c) _____ Thermal Expansion
d) _____ Thermal Conductivity

Question 34: Fireclay brick which has a PCE not lower than Cone 33, and which meet certain other requirements as
outlined in ASTM C 27 is
√
a). _____Superduty Firebrick
b) _____ Semi-silica brick
c) _____ Lowduty Firebrick
d) _____ Mediumduty Firebrick

Question 35: The party or individual who has no commercial affiliation with the contractor or manufacturer, unless
otherwise agreed by the owner is
a). _____Contractor
b) _____
√ Inspector
c) _____ Supervisor
d) _____ Engineer

Question 36: Metallic anchors like S-Bar, Hexcel, Curl and Tacko anchors used as an alternative in thin layer erosion
resistant lining is
a). _____Hex-mesh
b) _____ Cyclone anchors
c) _____ Erosion lining anchors
d) _____
√ Hexalt anchors
Question 37: The inclination of pneumatic gunning test panel approximately 6 ft (1.9 m) above ground level is
a). _____30 degrees
√ 45 degrees
b) _____
c) _____ 40 degrees
d) _____ 35 degrees

Question 38: At the refractory application site, the temperature of the air and shell to be between
o o
a). _____50
√ F (10 C) minimum and 90oF (32oC) maximum
b) _____ 52 F (11 C) minimum and 92oF (33oC) maximum
o o

c) _____ 59oF (15oC) minimum and 104oF (40oC) maximum

d) _____ 48oF (8oC) minimum and 86oF (30oC) maximum

Question 39: During vibration casting the time between successive mix to be no more than
a). _____20 minutes
b) _____ 15 minutes
c) _____ 12 minutes
d) _____
√ 10 minutes
Question 40: The cold crushing strength testing shall be in accordance with
a). _____ASTM C 113
√ ASTM C 133
b) _____
c) _____ ASTM C 24
d) _____ ASTM C 704

Question 41: Which one of the following refractory having higher abrasion resistance

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 API 936– Model Exam
a). _____High Silica brick
b) _____
√ High-alumina brick
c) _____ Super-duty firebrick
d) _____ Conventional high-cement castable

Question 42: The newly installed hydraulic bonded castable lining shall be cured for a minimum period of
a). _____12 hrs
b) _____ 10 hrs
√ 24 hrs
c) _____
d) _____ 20 hrs

Question 43: A fireclay brick which has a PCE value not lower than Cone 29, and not higher than 31 to 31 ½ is
a). _____Mediumduty Firebrick
√ Lowduty Firebrick
b) _____
c) _____ Highduty Firebrick
d) _____ Normal Firebrick

Question 44: After each run of Abrasion resistance test as per ASTM C 704, silicon carbide abrading media retained
on ASTM standard sieve No. 20 to be
a). _____Re-used
b) _____
√ Discarded
c) _____ Sampled
d) _____ Passed

Question 45: Scheduling of material qualification tests and delivery of those materials and test results to the site is the
responsibility of
a). _____Independent laboratory
b) _____ Inspector
c) _____
√ Contractor
d) _____ Owner

Question 46: Demonstration of capabilities in simulated installation by the Contractor, which is witnessed and
inspected by the Inspector, is
a). _____Material qualification
b) _____ As-installed testing
c) _____
√ Applicator qualification
d) _____ Specification qualification

Question 47: Downward gunning below horizontal is prohibited unless agreed to otherwise by the Owner, beyond
√
a). _____30 degrees
b) _____ 25 degrees
c) _____ 40 degrees
d) _____ 35 degrees

Question 48: Test method for Workability Index of Fireclay and High alumina Plastic refractory is
a). _____ASTM C 113
b) _____ ASTM C 179
c) _____
√ ASTM C 181
d) _____ ASTM C 134

Question 49: The newly installed heat-setting, plastic refractory lining shall be allowed to air dry at an ambient
temperature of 70oF – 85oF (20oC-30oC) for a minimum period of
a). _____24
√ hrs
b) _____ 6 hrs
c) _____ 12 hrs
d) _____ 20 hrs

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 API 936– Model Exam

Question 50: Individual in a dry gun operation who controls material charging, flow rate and air flow is called as
a). _____Nozzle man
b) _____
√ Gun man
c) _____ Crafts man
d) _____ Air Controller

Question 51: Fireclay brick which has a PCE value not lower than Cone 31½ , nor above 32½ - 33 is
a). _____Mediumduty Firebrick
b) _____ Lowduty Firebrick
√ Highduty Firebrick
c) _____
d) _____ Superduty Firebrick

Question 52: Refractory castable having densities between 50 lb./ft3 (800 kg/m3) and 100 lb./ft3 (1602 kg/m3) is
a). _____Normal-weight refractory castable
b) _____ Light weight castable
c) _____
√ Medium weight castable
d) _____ Very light weight castable

Question 53: A heat treatment which causes adjacent particles of material to cohere, at a temperature below that of
complete melting is called as
a). _____Sintering
√
b) _____ Congruent melting
c) _____ Conversion
d) _____ Vitrification

Question 54: The property of a material that enables it to be moulded into desired forms, which are retained after the
pressure of moulding has been released, is
a). _____Extrusive
b) _____ Elasticity
c) _____ Setting
√ Plasticity
d) _____

Question 55: The structural portion of a furnace, which withstands the thrust of an arch is
a). _____Crown
b) _____
√ Abutment
c) _____ Striking point
d) _____ Soffit

Question 56: The ratio of tensile stress to elongation within the elastic limit is known as
√
a). _____Young’s modulus
b) _____ Modulus of rupture
c) _____ Bulk Density
d) _____ Compressive strength

Question 57: Which one of the following is not a basic refractory

a). _____Periclase
b) _____
√ Chrome
c) _____ Forsterite
d) _____ Dolomite

Question 58: Aggregate and/or cement, which bounces away from a surface against which refractory is being
projected by gunning is
a). _____Ash
b) _____ Wastage
√ Rebound
c) _____
d) _____ Dust

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Question 59: A silicious glassy rock composed of small spheroids, when heated to a suitable temperature, expands to
form a lightweight glassy material with cellular structure is
a). _____Vermiculite
b) _____ Fused Silica
c) _____ Asbestos
√ Perlite
d) _____

Question 60: The size of test panel for a gun qualification to be

a). _____≥
√ 24 in. x 24 in. (610mm x 610mm) with thickness and anchors the same as the actual lining
b) _____ ≥ 20 in. x 20 in. (508mm x 508mm) with thickness and anchors the same as the actual lining c) _____ ≥ 26 in. x
26 in. (660mm x 660mm) with thickness and anchors the same as the actual lining
d) _____ ≤ 24 in. x 24 in. (610mm x 610mm) with thickness and anchors the same as the actual lining

Question 61: Three of the following are responsibilities of Inspector. Which one is not
a). _____Hammer test newly installed linings before and after dry-out, and report any anomalies to
the owner.
b) _____
√ Make engineering decisions contrary or in addition to specified requirements.
c) _____ Monitor qualification and production work conducted by the manufacturer and contractor to
ensure compliance with job specifications and agreed to quality standards.
d) _____ Notify the owner and the contractor in a timely manner of any work deficiencies or potential
deficiencies based on monitoring of material qualifications and the installation process.

Question 62: Inspection technique where, welded metal anchors are physically bent at the weld point to verify the
weld integrity to the casing is called as
a). _____Weld test
b) _____ Anchor test
c) _____ Physical test
√ Bend test
d) _____

Question 63: Which one of the following allow the moisture to escape more rapidly and reduce the chances of bloating
or sheeting in a plastic refractory lining during initial heating.
a). _____Organic fibres
b) _____ Pore Structures
c) _____ Steel fibres
√ Vent holes
d) _____

Question 64: A dry mixture of a binder, usually calcium aluminate cement, and selected and proportioned refractory
aggregare(s) which when mixed with water produces a solid is,
a). _____Castable refractory
√
b) _____ Ramming mass
c) _____ Concrete mix
d) _____ Ceramic binder

Question 65: The process of reduction of refractory materials to fine particles is called as
a). _____Screening
b) _____ Compaction
c) _____
√ Comminution
d) _____ Crushing

Question 66: The anti freeze agent added with plastics during the installation at winter seasons is
a). _____Boric acid
b) _____
√ Methanol
c) _____ Waxes
d) _____ Chromic acid

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Question 67: The ratio of heat capacity of the material to that of water is called as
a). _____Thermal conductivity
√ Specific heat
b) _____
c) _____ Thermal gradient
d) _____ Specific capacity

Question 68: The smelting of copper produces slag, whose chemistry is,
a). _____Acidic
b) _____ Neutral
c) _____ Both acidic and basic
√ Basic
d) _____

Question 69: A layer of coat of refractory, usually troweled on, which is applied to an existing lining in a attempt to
extend the lining life is,
√
a). _____Overlay
b) _____ Flash coat
c) _____ Overspray
d) _____ Over coat

Question 70: A substance that causes or accelerates a chemical change without being permanently affected by the reaction
is,
√
a). _____Catalyst
b) _____ Flux
c) _____ Reactor
d) _____ Chemical

Question 71: The property of porous materials which permits the passage of gases and liquids under pressure is,
a). _____Porosity
b) _____ Emissivity
c) _____
√ Permeability
d) _____ Conductivity

Question 72: The high strength bond that is developed between materials, as a result of thermochemical reactions at
elevated temperatures is,
√
a). _____Ceramic bond
b) _____ Chemical bond
c) _____ Hydraulic bond
d) _____ Thermal bond

Question 73: Burned refractory material, usually calcined clay or crushed brick bats is
a). _____Frit
b) _____
√ Grog
c) _____ Filler
d) _____ Aggregate

Question 74: Refractory concrete having low density and low thermal conductivity is
√
a). _____Insulating castable
b) _____ Medium weight castable
c) _____ Low density castable
d) _____ Normal weight castable

Question 75: Refractory concrete using calcium aluminate cement as binder was developed during,
a). _____1930’s

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 API 936– Model Exam
b) _____ 1910’s
c) _____ 1940’s
d) _____
√ 1920’s

Question 76: Condition of pre-set refractory in which gravitational forces cause in to lose its desired shape is called as
a). _____Fluxing
b) _____ Sagging
√ Slumping
c) _____
d) _____ Slagging

Question 77: What will be the grade of purity of calcium aluminate cement, if it has 48 – 62% Al2O3; 1 – 3% Fe2O3; 26 –
39% CaO and 3.5 – 9-0% SiO2
a). _____Intermediate purity
√
b) _____ High purity
c) _____ Low purity
d) _____ Very high purity

Question 78: When a castable develops its hydraulic bond because of chemical reactions between the calcium aluminate
cement and water, which of the following form is stable and preferable
a). _____C
√ 3AH6
b) _____ CAH10
c) _____ C2AH8
d) _____ C4AH4

Question 79: The acceptable distance of the nozzle from the receiving surface during shotcreating is
a). _____5-6 ft. (1.5 – 1.8 mtr.)
b) _____
√ 3-4 ft. (0.9 – 1.2 mtr.)
c) _____ 2-3 ft. (0.6 – 0.9 mtr.)
d) _____ 6-7 ft. (1.8 – 2.1 mtr.)

Question 80: As per the classification of light weight castable based on ASTM C401, material having Permanent linear
shrinkage not more than 1.5% when fired for 5 hrs at 2300oF (1260oC) and maximum bulk density 95 lbs/cu.ft (1.52
mg/m3) after drying at 220oF-230 oF (105oC-110oC) is
a). _____Class O
b) _____ Class V
√ Class Q
c) _____
d) _____ Class P

Question 81: The apparent porosity of most light weight refractory castable after drying at 220oF-230 oF (105oC-105oC) is
in the range of
a). _____40%
√ – 60%
b) _____ 20% – 30%
c) _____ 10% – 20%
d) _____ 60% – 80%

Question 82: Method of refractory concrete installation using conventional shotcrete equipment procedures and replacing
the nozzle tip by a placing head in order to reduce the material velocity is
a). _____Low velocity casting

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b) _____ Shotcrete installation
c) _____ Casting installation
√ Pneumatic gun casting
d) _____

Question 83: The addition of steel fibres into the refractory castable tends to reduce the
a). _____Permeability
b) _____ Conductivity
c) _____
√ Workability
d) _____ Emissivity

Question 84: Which one of the following cannot be assured on the installation of refractory concretes over conventional
pre-fired refractories
a). _____A minimum, or elimination of joints
b) _____ efficient and economical maintenance
c) _____ Reduction in installation and construction time
√ Final product quality
d) _____

Question 85: In the steel making, the equipment which is processing iron ore into metallic iron is
a). _____Electric arc furance
√ Blast furnace
b) _____
c) _____ Cupola
d) _____ Open hearth furnace

Question 86: The test, which, indicates the flextural strength of a refractory material is known as
a). _____Cold
√ modulus of rupture
b) _____ Compressive strength
c) _____ Abrasion resistance
d) _____ Thermal resistance

Question 87: Permanent linear change of refractory materials are measured in accordance with
a). _____ ASTM C-24
b) _____ ASTM C-134
√ ASTM C-113
c) _____
d) _____ ASTM C-133

Question 88: The party supplying the refractory lining materials to be installed in the equipment of the owner is called as
a). _____ Manufacturer
b) _____ Contractor
√
c) _____ Third party
d) _____ Inspector

Question 89: In the absence of manufacturer’s mix temperature limits, mix temperature shall be between
a). _____80oF - 100oF (27oC - 38oC)
b) _____ 70oF - 90oF (21oC - 32oC)
c) _____ 50oF - 70oF (10oC - 21oC)
√ 60oF - 80oF (15oC - 27oC)
d) _____

Question 90: Which one of the following metallic anchor does not require colour coding
a). _____ Incoloy
b) _____ Carbon steel
√
c) _____ Stainless steel
d) _____ Inconel

Question 91: Destructive chemical reaction between refractories and external agencies at high temperatures, resulting in
the liquid formation is called as
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a). _____Slagging
b) _____ Slumping
c) _____ Fluxing
d) _____ Fusion

Question 92: Refractory material components which are proportioned and mixed on the site just prior to the addition of
water is called as
a). _____Castable mix
b) _____ Gun mix
√ Field mix
c) _____
d) _____ Mortar mix

Question 93: Refractory material cast into a mock-up may be stripped and visually inspected after a minimum curing
period of
a). _____24 hrs
b) _____ 6 hrs
c) _____
√ 12 hrs
d) _____ 20 hrs

Question 94: A wire mesh basket of ½” (13mm) wire and size about 12 in. x 12 in. (300mm x 300mm) and at least 4”
(100mm) deep is recommended test sample for
a). _____Casting installations
b) _____ Ramming installations
c) _____ Mouldable refractory installations
√ Gunning installations
d) _____

Question 95: As per ASTM, the specimen size for testing modulus of rupture is
a). _____9”
√ x 4 ½” x 2 ½” or 3” (228 x 114 x 64 or 76mm)
b) _____ 9” x 3” x 2 ½” or 3” (228 x 76 x 64 or 76mm)
c) _____ 4 ½” x 2 ½” x 2 ½” or 3” (114 x 64 x 64 or 76mm)
d) _____ 9” x 2 ½” x 2 ½” or 3” (228 x 64 x 64 or 76mm)

Question 96: The colour coding of alloy 310 is

a). _____1 solid green, 1 solid brown
b) _____ 1 solid black, 1 solid brown
c) _____
√ 1 solid green, 1 solid orange
d) _____ 1 solid black, 1 solid orange

Question 97: The problem with free cristobalite in fireclay refractories, which causes deterioration on continued
reheating and cooling is called
a). _____Dusting
b) _____ Disintegration
c) _____ Deterioration
d) _____
√ Dunting
Question 98: Double carbonate of calcium and magnesium is
a). _____Forsterite
b) _____
√ Dolomite
c) _____ Periclase
d) _____ Spinel

Question 99: A change in crystal form without any change in chemical composition is
a). _____Conversion
b) _____ Congruent melting
c) _____
√ Inversion
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d) _____ Incongruent melting

Question 100: the temperature at which crystalline and liquid phases having the same composition coexist in
equilibrium is called as
a). _____Softening point
b) _____ Eutectic temperature
c) _____ Fluxing temperature
d) _____
√ Melting point

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